Download 545rfe Transmission Manual PDF

Title545rfe Transmission Manual
TagsManual Transmission Transmission (Mechanics) Automatic Transmission Clutch Machines
File Size3.6 MB
Total Pages114
Document Text Contents
Page 1

OIL PUMP FRONT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 436

OUTPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 436
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 436
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 437

TOW/HAUL OVERDRIVE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 437
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 437
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 438

PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 438
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 438

PLANETARY GEARTRAIN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 440
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 441
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 442
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 442
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 443

SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 444
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 444

SOLENOID SWITCH VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 444
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 444

SOLENOIDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 444

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 445
TORQUE CONVERTER

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 445
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 449
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 451

TRANSMISSION CONTROL RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 451
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 451

TRANSMISSION RANGE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 451
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 451

TRANSMISSION SOLENOID/TRS ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 452
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 452
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 454

TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 454
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 454

VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 454
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 454
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 457
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 460
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 463

AUTOMATIC TRANSMISSION -
45RFE/545RFE

DESCRIPTION
The 45RFE/545RFE automatic transmissions is a

sophisticated, multi-range, electronically controlled
transmission which combines optimized gear ratios
for responsive performance, state of the art efficiency
features and low NVH. Other features include driver
adaptive shifting and three planetary gear sets to
provide wide ratio capability with precise ratio steps
for optimum driveability. The three planetary gear
sets also make available a unique alternate second
gear ratio. The primary 2nd gear ratio fits between
1st and 3rd gears for normal through-gear accelera-
tions. The alternate second gear ratio (2prime) allows
smoother 4-2 kickdowns at high speeds to provide
2nd gear passing performance over a wider highway
cruising range.

The hydraulic portion of the transmission consists
of the transmission fluid, fluid passages, hydraulic
valves, and various line pressure control components.

The primary mechanical components of the trans-
mission consist of the following:

• Three multiple disc input clutches
• Three multiple disc holding clutches
• Five hydraulic accumulators
• Three planetary gear sets
• Dual Stage Hydraulic oil pump
• Valve body
• Solenoid pack
The TCM is the “heart” or “brain” of the electronic

control system and relies on information from vari-
ous direct and indirect inputs (sensors, switches, etc.)
to determine driver demand and vehicle operating
conditions. With this information, the TCM can cal-
culate and perform timely and quality shifts through
various output or control devices (solenoid pack,
transmission control relay, etc.).

21 - 350 AUTOMATIC TRANSMISSION - 45RFE/545RFE DR

Page 57

• failure to clean dipstick and fill tube when
checking level

• engine coolant entering the fluid
• internal failure that generates debris
• overheat that generates sludge (fluid break-

down)
• failure to replace contaminated converter after

repair
The use of non-recommended fluids can result in

transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.

The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.

Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.

The torque converter should also be replaced when-
ever a failure generates sludge and debris. This is
necessary because normal converter flushing proce-
dures will not remove all contaminants.

STANDARD PROCEDURE

STANDARD PROCEDURE - FLUID LEVEL
CHECK

Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.

Improper filling can also raise the fluid level too
high. When the transmssion has too much fluid, the
geartrain churns up foam and cause the same condi-
tions which occur with a low fluid level.

In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transmission vent where it may be mis-
taken for a leak.

After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.

The transmission has a dipstick to check oil level.
It is located on the right side of the engine. Be sure
to wipe all dirt from dipstick handle before removing.

The torque converter fills in both the P (PARK)
and N (NEUTRAL) positions. Place the selector lever

in P (PARK) to be sure that the fluid level check is
accurate. The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground. At normal operating temperature
(approximately 82 C. or 180 F.), the fluid level is cor-
rect if it is in the HOT region (cross-hatched area) on
the oil level indicator. The fluid level will be approx-
imately at the upper COLD hole of the dipstick at
70° F fluid temperature.

NOTE: Engine and Transmission should be at nor-
mal operating temperature before performing this
procedure.

(1) Start engine and apply parking brake.
(2) Shift the transmission into DRIVE for approxi-

mately 2 seconds.
(3) Shift the transmission into REVERSE for

approximately 2 seconds.
(4) Shift the transmission into PARK.
(5) Hook up DRBt scan tool and select transmis-

sion.
(6) Select sensors.
(7) Read the transmission temperature value.
(8) Compare the fluid temperature value with the

chart. (Fig. 71)
(9) Adjust transmission fluid level shown on the

dipstick according to the Transmission Fluid Temper-
ature Chart.

NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.

(10) Check transmission for leaks.

STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT

For proper service intervals (Refer to LUBRICA-
TION & MAINTENANCE/MAINTENANCE SCHED-
ULES - DESCRIPTION).

REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Place a large diameter shallow drain pan

beneath the transmission pan.
(3) Remove bolts holding front and sides of pan to

transmission.
(4) Loosen bolts holding rear of pan to transmis-

sion.
(5) Slowly separate front of pan away from trans-

mission allowing the fluid to drain into drain pan.
(6) Hold up pan and remove remaining bolts hold-

ing pan to transmission.
(7) While holding pan level, lower pan away from

transmission.

21 - 406 AUTOMATIC TRANSMISSION - 45RFE/545RFE DR

FLUID AND FILTER (Continued)

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